U.S. patent application number 11/984768 was filed with the patent office on 2008-05-29 for method of and apparatus for working structure.
This patent application is currently assigned to TOWA CORPORATION. Invention is credited to Shinya Kunimatsu, Makoto Matsuo, Hisayoshi Onishi.
Application Number | 20080121078 11/984768 |
Document ID | / |
Family ID | 39148585 |
Filed Date | 2008-05-29 |
United States Patent
Application |
20080121078 |
Kind Code |
A1 |
Kunimatsu; Shinya ; et
al. |
May 29, 2008 |
Method of and apparatus for working structure
Abstract
In a method of working a structure, a mold material is mounted
on a mold material mount portion of a cutting/working apparatus and
rotated about the C-axis serving as the rotation center while a
cutting tool is driven and moved in directions X and Y. Then, a
desired position of the mold material is cut with the cutting tool
at a relatively formed desired cutting speed and elliptically
vibrated/cut with the cutting tool, for forming a Fresnel lens
molding cavity having an opening of a desired shape and a working
surface (concave surface, for example) of a desired shape.
According to this method, the productivity of an optical component
mold employed as the structure can be efficiently improved when the
mold for molding an optical component such as a Fresnel lens is
worked by cutting the mold material employed as a workpiece with
the cutting tool in a four-spindle lathe-type cutting/working
apparatus including X-, Y-, Z- and C-axes of rotation.
Inventors: |
Kunimatsu; Shinya;
(Kyoto-shi, JP) ; Onishi; Hisayoshi; (Kyoto-shi,
JP) ; Matsuo; Makoto; (Kyoto-shi, JP) |
Correspondence
Address: |
BIRCH STEWART KOLASCH & BIRCH
PO BOX 747
FALLS CHURCH
VA
22040-0747
US
|
Assignee: |
TOWA CORPORATION
|
Family ID: |
39148585 |
Appl. No.: |
11/984768 |
Filed: |
November 21, 2007 |
Current U.S.
Class: |
83/13 ;
83/648 |
Current CPC
Class: |
B24B 1/04 20130101; B24B
13/046 20130101; Y10T 83/889 20150401; Y10T 83/04 20150401; Y10T
82/25 20150115; B23B 2265/16 20130101; B23B 1/00 20130101; Y10T
82/10 20150115; B23C 3/00 20130101; B23B 2226/31 20130101; B23B
29/125 20130101 |
Class at
Publication: |
83/13 ;
83/648 |
International
Class: |
B26D 7/00 20060101
B26D007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 24, 2006 |
JP |
2006-317162(P) |
Claims
1. A method of working a structure with a working apparatus at
least having three rectilinear drive spindles orthogonal to each
other and a rotary spindle rotationally driving a workpiece by
cutting said workpiece in a state rotated about a C-axis employed
as the axis of rotation with a cutting tool driven in directions X
and Y while relatively adjusting a desired depth of cut with
respect to said workpiece in a direction Z thereby forming a cavity
of a desired shape in said workpiece, comprising the steps of:
driving said cutting tool in said directions X and Y and
synchronously rotating said cutting tool in the same rotational
direction as said C-axis rotation; and cutting a desired position
of said workpiece with said cutting tool thereby forming said
cavity of said desired shape in said workpiece, wherein said step
of cutting said desired position of said workpiece with said
cutting tool includes the step of generating elliptical vibration
on the cutting edge of said cutting tool thereby elliptically
vibrating/cutting and working said workpiece at a relative desired
cutting speed.
2. The method of working a structure according to claim 1,
relatively forming said desired cutting speed by a relative cutting
feed rate resulting from the traveling speeds of said workpiece and
said cutting tool and the vibration speed of the locus of said
elliptical vibration in said step of cutting said desired position
of said workpiece with said cutting tool.
3. The method of working a structure according to claim 1,
arranging the cutting edge of said cutting tool on the
three-o'clock position in an opening of a molding cavity formed
with said cutting tool in said step of cutting said desired
position of said workpiece with said cutting tool.
4. A method of working a structure with a working apparatus at
least having three rectilinear drive spindles orthogonal to each
other and a rotary spindle rotationally driving a workpiece by
cutting said workpiece in a state rotated about a C-axis employed
as the axis of rotation with a cutting tool driven in directions X
and Y while relatively adjusting a desired depth of cut with
respect to said workpiece in a direction Z thereby forming a cavity
of a desired shape in said workpiece, comprising the steps of:
driving said cutting tool in said directions X and Y and
synchronously rotating said cutting tool in the same rotational
direction as said C-axis rotation; cutting a desired position of
said workpiece with said cutting tool thereby forming said cavity
of said desired shape in said workpiece; and high-speed-milling
said workpiece at a relative desired cutting speed in said step of
cutting said desired position of said workpiece with said cutting
tool.
5. The method of working a structure according to claim 4,
relatively forming said desired cutting speed by a relative cutting
feed rate resulting from the traveling speeds of said workpiece and
rotated said cutting tool and the rotational speed of a rotary
blade in said step of cutting said desired position of said
workpiece with said cutting tool.
6. The method of working a structure according to claim 4,
arranging the cutting edge of said cutting tool in the
three-o'clock direction in an opening of a molding cavity formed
with said cutting tool in said step of cutting said desired
position of said workpiece with said cutting tool.
7. An apparatus for working a structure, comprising: three
rectilinear drive spindles orthogonal to each other; a rotary
spindle rotationally driving a workpiece; and a cutting tool driven
in directions X and Y while relatively adjusting a desired depth of
cut with respect to said workpiece in a direction Z, wherein said
cutting tool is provided with an elliptical vibration generating
portion generating a locus of elliptical vibration.
8. An apparatus for working a structure, comprising: three
rectilinear drive spindles orthogonal to each other; a rotary
spindle rotationally driving a workpiece; and a cutting tool driven
in directions X and Y while relatively adjusting a desired depth of
cut with respect to said workpiece in a direction Z, wherein a
rotary cutting tool for high-speed milling is provided as said
cutting tool.
Description
[0001] This nonprovisional application is based on Japanese Patent
Application No. 2006-317162 filed with the Japan Patent Office on
Nov. 24, 2006, the entire contents of which are hereby incorporated
by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method of working a
structure for working a workpiece into a structure having a cavity
of a desired shape, and more particularly, it relates to a method
of working an optical component mold (structure) for forming an
optical component such as a Fresnel lens or an LED component by
molding an optical element (electronic component) such as a
light-emitting diode (LED) chip with a resin material such as
silicone resin, for example.
[0004] 2. Description of the Background Art
[0005] Working of a mold material with a conventional four-spindle
lathe-type cutting/working apparatus is now described with
reference to FIGS. 13A and 13B. In general, a lathe-type
cutting/working apparatus 101 (four-spindle lathe-type
cutting/working apparatus driven at least in four directions along
the X-, Y-, Z- and C-axes, for example) is employed for working a
mold material (workpiece) 102 with a cutting tool (turning tool)
103 such as a single-crystalline diamond tool thereby working an
optical component mold (structure) for molding an optical component
such as a Fresnel lens. This method is carried out in the following
manner, for example:
[0006] First, mold material 102 is mounted on a mold material mount
portion 104 of lathe-type cutting/working apparatus 101, and
rotated about the C-axis (rotation center 105) of cutting/working
apparatus 101 in a rotational direction (clockwise direction 109 in
FIG. 13A). Then, mold material 102 is cut along center 105 forming
the axis of rotation of rotated mold material 102 with cutting tool
103, thereby forming a Fresnel lens (optical component) molding
cavity 106 having a circular opening and a working surface
corresponding to the shape of the Fresnel lens on a work surface
107 of mold material 102.
[0007] At this time, a desired number of peripheral grooves each
having a desired shape are formed on the working surface of cut
cavity 106 concentrically with center 105 of the axis of rotation
(C-axis), for forming mold material 102 (cavity part 108) having
one cavity 106.
[0008] Therefore, a cavity block (split mold) having a desired
number of cavities 106 is formed by aligning and combining the
desired number of cavity parts 108 each having one cavity 106 with
each other.
[0009] According to another working method employing
cutting/working apparatus 101, mold material 102 is mounted on mold
material mount portion 104 of cutting/working apparatus 101 and
rotated about the C-axis of apparatus 101 as described above. Then,
the steps of cutting one cavity 106 about rotation center 105 of
mold material 101 with cutting tool 103 and thereafter moving
(shifting) the worked position of worked mold material 102 are so
repeated as to form a cavity block (split mold) having a desired
number of cavities 106 by working the desired number of cavities
106 on mold material 102.
[0010] Such working of the mold material with the aforementioned
conventional four-spindle lathe-type cutting/working apparatus is
disclosed in FIG. 4 of Japanese Patent Laying-Open No. 07-241918
(1995) and description related thereto, for example.
[0011] The aforementioned working with lathe-type cutting/working
apparatus 101 may be replaced with electron beam lithography.
However, the electron beam lithography requires a considerable
number of trials and errors in order to obtain optimum exposure
distribution, and worked cavities 106 are small. Therefore, a mold
formed by this lithography is so inferior in working efficiency
that the same is not yet put into practice.
[0012] As hereinabove described, an optical component mold (split
mold serving as a structure) for molding an optical component such
as a Fresnel lens is generally worked with lathe-type
cutting/working apparatus 101.
[0013] However, setup times are required for working a desired
number (a large number) of cavity parts 108 (single cavities 106)
respectively as hereinabove described, and a mold (split mold)
having a desired number (a plurality) of cavities cannot be
efficiently cut for efficiently manufacturing the optical component
mold. Therefore, the productivity of the optical component mold
(structure) cannot be efficiently improved.
[0014] When cavity parts 108 are aligned and combined with each
other as described above, a step is easily formed on the
combinational reference surface (work surface 107) of the formed
cavity block. Therefore, a long time is required for flattening
(flushing) this reference surface (107). Consequently, the
productivity of the optical component mold (structure) cannot be
efficiently improved in the working of (the working method for) the
optical component mold.
[0015] Further, it is remarkably difficult to precisely arrange
cavities 106 formed in mold material (workpiece) 102 at a desired
pitch.
[0016] In the working of the optical component mold for molding an
optical component such as a Fresnel lens, the working surface of
the Fresnel lens must be mirror-finished, in order to improve the
transparency of the lens or the reflectivity of a reflector.
[0017] In the aforementioned working, however, no sufficient
desired cutting speed is obtained particularly in a case of cutting
a hardly cuttable material such as cemented carbide, and hence
working resistance is so increased that the working surface
(concave surface, for example) cannot be mirror-finished.
[0018] In the case of working the optical component mold,
therefore, the working surface formed on the mold cannot be
efficiently mirror-finished, and a high-quality working surface
cannot be efficiently worked.
[0019] In relation to the optical component mold (structure) for
molding an optical component such as a Fresnel lens, further,
working of an optical component molding cavity having an opening of
a desired shape and a nonspherical working surface may be required,
in addition to the cutting of cavity 106 having an axisymmetric
circular opening and a spherical working surface (concave
surface).
[0020] However, such a cavity cannot be efficiently worked in the
aforementioned working method employing rotation center 105 as the
axis of rotation. Thus, an optical component molding cavity having
an opening of a desired shape and a nonspherical working surface
cannot be efficiently worked in the working (method) of the optical
component mold.
SUMMARY OF THE INVENTION
[0021] An object of the present invention is to efficiently improve
the productivity of a structure by efficiently cutting a structure
having a desired number (a plurality) of cavities in a method of
working a structure.
[0022] Another object of the present invention is to efficiently
work a high-quality working surface by efficiently mirror-finishing
a working surface of a structure in working of a structure.
[0023] Still another object of the present invention is to
efficiently work a cavity having an opening of a desired shape and
a nonspherical working surface in working of a structure.
[0024] A further object of the present invention is to efficiently
improve the productivity of an optical component mold by
efficiently cutting a mold (split mold) having a desired number (a
plurality) of cavities in working of an optical component mold.
[0025] A further object of the present invention is to efficiently
work a high-quality working surface by efficiently mirror-finishing
a working surface of a mold in working of an optical component
mold.
[0026] A further object of the present invention is to efficiently
work a an optical component molding cavity having an opening of a
desired shape and a nonspherical working surface in working of an
optical component mold.
[0027] In order to solve the aforementioned technical problems,
provided according to an aspect of the present invention is a
method of working a structure with a working apparatus at least
having three rectilinear drive spindles orthogonal to each other
and a rotary spindle rotationally driving a workpiece by cutting
the workpiece in a state rotated about a C-axis employed as the
axis of rotation with a cutting tool driven in directions X and Y
while relatively adjusting a desired depth of cut with respect to
the workpiece in a direction Z thereby forming a cavity of a
desired shape in the workpiece. This method comprises the steps of
driving the cutting tool in the directions X and Y and
synchronously rotating the cutting tool in the same rotational
direction as the C-axis rotation, cutting a desired position of the
workpiece with the cutting tool thereby forming the cavity of the
desired shape in the workpiece and generating elliptical vibration
on the cutting edge of the cutting tool thereby elliptically
vibrating/cutting and working the workpiece at a relative desired
cutting speed in the step of cutting the desired position of the
workpiece with the cutting tool.
[0028] According to this method of working a structure, the desired
cutting speed is relatively formed by a relative cutting feed rate
resulting from the traveling speeds of the workpiece and the
cutting tool and the vibration speed of the locus of the elliptical
vibration in the step of cutting the workpiece with the cutting
tool.
[0029] In order to solve the aforementioned technical problems,
provided according to another aspect of the present invention is a
method of working a structure with a working apparatus at least
having three rectilinear drive spindles orthogonal to each other
and a rotary spindle rotationally driving a workpiece by cutting
the workpiece in a state rotated about a C-axis employed as the
axis of rotation with a cutting tool driven in directions X and Y
while relatively adjusting a desired depth of cut with respect to
the workpiece in a direction Z thereby forming a cavity of a
desired shape in the workpiece. This method comprises the steps of
driving the cutting tool in the directions X and Y and
synchronously rotating the cutting tool in the same rotational
direction as the C-axis rotation, cutting a desired position of the
workpiece with the cutting tool thereby forming the cavity of the
desired shape in the workpiece and high-speed-milling the workpiece
at a relative desired cutting speed in the step of cutting the
desired position of the workpiece with the cutting tool.
[0030] According to this method of working a structure, the desired
cutting speed is relatively formed by a relative cutting feed rate
resulting from the traveling speeds of the workpiece and the
rotated cutting tool and the rotational speed of a rotary blade in
the step of cutting the desired position of the workpiece with the
cutting tool.
[0031] According to this method of working a structure, the cutting
edge of the cutting tool is arranged in the three o'clock direction
in an opening of a molding cavity formed with the cutting tool in
the step of cutting the desired position of the workpiece with the
cutting tool.
[0032] In order to solve the aforementioned technical problems, an
apparatus for working a structure according to still another aspect
of the present invention comprises at least three rectilinear drive
spindles orthogonal to each other, a rotary spindle rotationally
driving a workpiece and a cutting tool driven in directions X and Y
while relatively adjusting a desired depth of cut with respect to
the workpiece in a direction Z, and the cutting tool is provided
with an elliptical vibration generating portion generating a locus
of elliptical vibration.
[0033] An apparatus for working a structure according to a further
aspect of the present invention comprises at least three
rectilinear drive spindles orthogonal to each other, a rotary
spindle rotationally driving a workpiece and a cutting tool driven
in directions X and Y while relatively adjusting a desired depth of
cut with respect to the workpiece in a direction Z, and a rotary
cutting tool for high-speed milling is provided as the cutting
tool.
[0034] According to the present invention, a structure having a
desired number (a plurality) of cavities can be efficiently cut and
the productivity of the structure can be efficiently improved in
the method of working a structure.
[0035] According to the present invention, a working surface of a
structure can be efficiently mirror-finished and a high-quality
working surface can be efficiently worked in working of a
structure.
[0036] According to the present invention, a cavity including an
opening having a desired shape and a nonspherical working surface
can be efficiently worked in working of a structure.
[0037] According to the present invention, a mold (split mold)
having a desired number of cavities can be efficiently cut and the
productivity of an optical component mold can be efficiently
improved in working of an optical component mold.
[0038] According to the present invention, a working surface of a
mold can be efficiently mirror-finished and a high-quality working
surface can be efficiently worked in working of an optical
component mold.
[0039] According to the present invention, an optical component
molding cavity including an opening having a desired shape and a
nonspherical working surface can be efficiently worked in working
of an optical component mold.
[0040] The foregoing and other objects, features, aspects and
advantages of the present invention will become more apparent from
the following detailed description of the present invention when
taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 is a schematic perspective view schematically showing
a four-spindle lathe-type cutting/working apparatus according to an
embodiment of the present invention;
[0042] FIGS. 2A and 2B are a schematic front elevational view and a
schematic plan view of the apparatus shown in FIG. 1
respectively;
[0043] FIGS. 3A and 3B are schematic enlarged perspective views
schematically showing a principal part of the apparatus shown in
FIG. 1 in an enlarged manner for illustrating a state of cutting a
work surface of a rotated mold material;
[0044] FIGS. 4A and 4B are schematic enlarged perspective views
schematically showing the principal part of the apparatus shown in
FIG. 1 in an enlarged manner for illustrating the state of cutting
the work surface of the rotated mold material subsequently to FIGS.
3A and 3B;
[0045] FIG. 5 is a schematic enlarged side elevational view
schematically showing the principal part of the apparatus shown in
FIG. 1 in an enlarged manner for schematically illustrating a locus
of the forward end of a cutting tool on the work surface of the
rotated mold material;
[0046] FIG. 6A is a schematic enlarged side elevational view
schematically showing the principal part of the apparatus shown in
FIG. 1 in an enlarged manner for illustrating states of a letter
"P" shown on the work surface of the rotated mold material, and
FIG. 6B is another schematic enlarged side elevational view
schematically showing the principal part of the apparatus shown in
FIG. 1 in an enlarged manner for illustrating an opening of a
cavity cut on the work surface of the rotated mold material;
[0047] FIGS. 7A and 7B are a schematic enlarged front elevational
view and a schematic enlarged perspective view schematically
showing another principal part of the apparatus shown in FIG. 1 in
an enlarged manner for illustrating a state of elliptically
vibrating/cutting the mold material with the cutting tool;
[0048] FIGS. 8A and 8B are longitudinal sectional views each
schematically showing the mold material shown in FIG. 1 in an
enlarged manner for illustrating a state of working a Fresnel lens
mold;
[0049] FIG. 9 is a schematic perspective view schematically showing
the Fresnel lens mold (split mold) worked with the apparatus shown
in FIG. 1;
[0050] FIG. 10 is a schematic sectional view schematically showing
a compression mold comprising the Fresnel lens mold (split mold)
shown in FIG. 9;
[0051] FIG. 11 is a schematic side elevational view schematically
showing the work surface of the mold material mounted on the
apparatus shown in FIG. 1 for illustrating the position of a
Fresnel lens molding cavity on the work surface;
[0052] FIG. 12A is a schematic enlarged side elevational view
schematically showing a mold material mounted on a mold material
mount portion of an apparatus according to another embodiment of
the present invention in an enlarged manner, and FIG. 12B is a
schematic enlarged side elevational view schematically showing a
principal part of the mold material shown in FIG. 12A in a more
enlarged manner; and
[0053] FIG. 13A is a schematic enlarged side elevational view
schematically showing a mold material mounted on a mold material
mount portion of a conventional four-spindle lathe-type
cutting/working apparatus in an enlarged manner, and FIG. 13B is a
schematic enlarged perspective view schematically showing the mold
material shown in FIG. 13A in an enlarged manner.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0054] The basic structures of an apparatus for working a structure
and a working method employing the same according to each
embodiment of the present invention are now described. According to
the present invention, a working apparatus having three rectilinear
drive spindles (X-, Y- and Z-axes, for example) orthogonal to each
other and a rotary spindle (C-axis, for example) rotationally
driving a mold material (workpiece) (and a numerical control unit
driving these spindles) is employed. According to the present
invention, an optical component mold (structure) resin-molding an
optical component such as a Fresnel lens is worked by cutting a
mold material with a cutting tool in a four-spindle lathe-type
cutting/working apparatus driving the cutting tool at least in four
directions along X-, Y-, Z- and C-axes, for example.
[0055] In the working method according to the present invention, a
mold material (workpiece) is mounted on a mold material mount
portion, which in turn is rotated clockwise, for example, about the
C-axis serving as the rotation center, thereby rotating the mold
material at a desired rotational speed.
[0056] At this time, a desired portion on the work surface of the
mold material is rotated about the C-axis serving as the rotation
center at a desired rotational speed (desired peripheral speed). At
the same time, an arbitrary point of an opening of a cavity cut on
a desired position at a desired distance from the rotation center
of the C-axis is rotated/moved clockwise at a desired traveling
speed along the locus of the mold material in the opening of the
cavity correspondingly to the clockwise rotation of the mold
material mount portion (see FIGS. 6A and 6B).
[0057] Then, the cutting edge of the cutting tool is aligned with
the three o'clock position (cut position in the opening of the
cavity) in the opening of the cavity cut on the aforementioned
desired position of the rotated mold material. At the same time,
the cutting tool is independently driven in directions X and Y
respectively, so that the cutting edge of the cutting tool is
aligned with the three-o'clock position in the opening of the
rotated mold material.
[0058] At this time, the cutting edge of the cutting tool is
approximated to (or separated from) the desired position (center)
of the opening of the cavity from the outer peripheral edge of the
opening for moving and cutting the opening of the cavity on the
three-o'clock position. In other words, the cutting edge of the
cutting tool moves along the locus (spiral locus, for example) of
the cutting tool at a desired traveling speed.
[0059] On the three-o'clock position in the opening of the cavity,
therefore, the arbitrary point (mold material) in the cavity
opening regularly moves at a desired traveling speed while the
cutting edge of the cutting tool also moves at a desired traveling
speed. Thus, a relative desired cutting feed rate (cutting feed
rate resulting from both moving loci) can be formed between the
mold material and the cutting tool by the desired traveling speed
(locus) of the mold material and the desired traveling speed
(locus) of the cutting tool (synchronous control).
[0060] In other words, the desired cutting feed rate (moving locus)
can be relatively formed by the desired traveling speed (desired
rotational speed) in the mold material (workpiece) and the desired
traveling speed in the cutting tool [as to the cutting feed rate,
see arrow A (cutting direction) shown in FIGS. 7A and 7B].
[0061] In a working surface (concave surface, for example) of the
cavity formed by cutting the work surface of the mold material, a
desired depth of cut is adjusted by moving the mold material mount
portion (mold material) or the cutting tool in direction Z.
[0062] Then, a locus (vibration locus) of elliptical vibration
having a desired vibration speed is formed on the cutting edge of
the cutting tool, and the cavity is elliptically vibrated/cut with
the cutting edge of the cutting tool on a desired position
separated from the rotation center of the C-axis in the rotated
mold material by a desired distance.
[0063] At this time, the arbitrary point (cut position of the mold
material) in the cavity opening regularly moves downward
(clockwise) at the desired traveling speed (peripheral speed) on
the three-o'clock position in the cavity opening, while the cutting
in the locus of the elliptical vibration is directed upward
(counterclockwise) oppositely to the downward movement of the mold
material.
[0064] In other words, the "desired cutting speed (vibration
locus)" according to the present invention can be relatively (and
sufficiently) efficiently formed between the mold material and the
cutting tool by the relative cutting feed rate resulting from the
desired traveling speed (desired rotational speed) in the mold
material (workpiece) and the desired traveling speed of the cutting
tool and the desired vibration speed in the locus of the elliptical
vibration.
[0065] Therefore, the working surface of the mold can be
efficiently mirror-finished at the relative desired cutting speed
(vibration locus) according to the present invention by cutting the
mold material with the cutting tool while elliptically
vibrating/cutting the mold material.
[0066] As hereinabove described, the cutting edge of the cutting
tool can be moved along an arbitrary cutting tool locus by
independently driving the cutting tool in directions X and Y
respectively, whereby the cavity including the opening having the
desired shape can be formed on the desired position of the work
surface of the mold material separated from the rotation center by
the desired distance.
[0067] As hereinabove described, further, the cavity including the
desiredly shaped working surface can be formed by moving the mold
material or the cutting tool in direction Z and relatively
adjusting the same.
[0068] Therefore, an optical component molding cavity having a
desired shape, i.e., an opening of a desired shape and a working
surface (concave surface, for example) of a desired shape can be
formed by cutting on a desired portion of a work surface of a mold
material.
[0069] Further, a mold (split mold serving as a structure) having a
desired number of cavities (structure obtained by arranging a
plurality of cavities in the form of a matrix, for example) is cut
by repeating the working according to the present invention for
forming a desired number of cavities on a desired position of the
mold material.
[0070] According to the aforementioned structure, therefore, a mold
(split mold) having a desired number (a plurality) of cavities can
be efficiently cut for efficiently improving the productivity of an
optical component mold while a working surface of the mold can be
efficiently mirror-finished for efficiently working a high-quality
working surface in working of the optical component mold
(structure).
[0071] As hereinabove described, a cavity having a desired shape
can be formed in working of an optical component mold, whereby an
optical component molding cavity including an opening of a desired
shape and a nonspherical working surface can be efficiently
worked.
[0072] A small cavity including an opening having a small diameter
(.phi.100 .mu.m, for example) can be efficiently worked by
minimally setting the locus of the elliptical vibration generated
on the cutting edge of the cutting tool.
[0073] In other words, the said small cavity unworkable by general
cutting can be efficiently worked according to the present
invention.
[0074] When the cavity is cut on the desired position separated
from the rotation center by the desired distance with a lathe-type
cutting/working apparatus particularly in a hardly cuttable
material such as cemented carbide, the following problem may arise:
For example, the relative desired cutting feed rate (cutting speed)
formed between the mold material and the cutting tool by the
desired traveling speed (desired rotational speed) in (the desired
position of) the mold material and the desired traveling speed of
the cutting tool may be so insufficient that the working surface
(concave surface, for example) cannot be mirror-finished due to
increased working resistance.
[0075] However, the "desired cutting speed (vibration locus)"
according to the present invention can be relatively (and
sufficiently) efficiently formed between the mold material and the
cutting tool by the relative cutting feed rate resulting from the
desired traveling speed (desired rotational speed) in (the desired
position of) the mold material and the desired traveling speed of
the cutting tool and the desired vibration speed in the locus of
the elliptical vibration.
[0076] Further, a substantial undeformed chip thickness per cycle
of the locus of the elliptical vibration is reduced due to
intermittent cutting resulting from the elliptical vibration
cutting, whereby the working surface of the mold can be efficiently
mirror-finished.
[0077] When cutting the mold material, therefore, the working
surface of the mold can be efficiently mirror-finished and a
high-quality working surface can be efficiently worked by
elliptically vibrating/cutting the desired position of the mold
material at the relative "desired cutting speed" according to the
present invention.
[0078] In the aforementioned elliptical vibration, a rotational
locus (rotational direction for cutting) of a rotary blade of a
rotary cutting tool formed by high-speed milling can be employed in
place of the locus of the elliptical vibration.
[0079] In other words, the desired cutting speed can be relatively
formed by the relative cutting feed rate resulting from the desired
traveling speeds of the mold material (workpiece) and the rotary
cutting tool and a desired rotational speed of the rotary blade in
this high-speed milling.
[0080] In this case, functions/effects similar to those of the
aforementioned elliptical vibration structure can be attained.
[0081] Specific embodiments of the present invention are now
described in detail with reference to the drawings.
First Embodiment
[0082] FIGS. 1, 2A and 2B show a four-spindle lathe-type
cutting/working apparatus according to a first embodiment of the
present invention. FIGS. 3A, 3B, 4A, 4B, 5, 6A, 6B, 7A and 7B show
principal parts of the four-spindle lathe-type cutting/working
apparatus according to the first embodiment of the present
invention.
(Overall Structure of Lathe-Type Cutting/Working Apparatus)
[0083] The structure of a lathe-type cutting/working apparatus 1
according to the first embodiment of the present invention is
described with reference to FIGS. 1, 2A and 2B.
[0084] As shown in FIGS. 1, 2A and 2B, lathe-type cutting/working
apparatus 1 (four-spindle lathe-type cutting/working apparatus
having X-, Y-, Z- and C-axes in FIGS. 1, 2A and 2B) according to
the first embodiment of the present invention is provided with a
mold material mount mechanism (workpiece mount mechanism) 3 mounted
with a mold material (workpiece) 2 such as a steel material, a
cutting tool mount mechanism 5 mounted with a cutting tool 4 such
as a diamond tool and a base 6 for setting mold material mount
mechanism 3 and cutting tool mount mechanism 5.
[0085] Therefore, mold material 2 mounted on mold material mount
mechanism 3 can be cut with cutting tool 4 mounted on cutting tool
mount mechanism 5 on base 6, for cutting a cavity 17 on a desired
position 20 of a work surface 13 of mold material 2.
[0086] Cavity 17 includes an opening having a desired shape and a
working surface (concave surface, for example) having a desired
shape formed in this opening (desired range).
[0087] A control mechanism (numerical control unit, for example)
(not shown) transmitting a control instruction (signal) described
later to cutting/working apparatus 1 (mold material mount mechanism
3 and cutting tool mount mechanism 5, for example) and controlling
the same is provided so that apparatus 1 can be synchronously
controlled by this control mechanism.
[0088] Mold material mount mechanism 4 is provided with a mold
material mount portion 7 mounted with mold material 2 through a
proper member, a rotational driving portion (motor) 9 rotating mold
material mount portion (workpiece mount portion) 7 mounted with
mold material 2 in a desired direction about the C-axis formed by
the rotation center (core) 8 of mold material 2 and a mold material
mount mechanism body (workpiece mount mechanism body) 10 equipped
with mold material mount portion 6 and rotational driving portion
9, while a Z-directional driving portion (not shown) driving body
10 in direction Z is provided on mold material mount mechanism body
10.
[0089] Therefore, mold material 2 mounted on mold material mount
portion 7 can be rotated in the desired direction about rotation
center 8 of the C-axis at a desired rotational speed (desired
traveling speed) in mold material mount mechanism 3, and can be
reciprocatively moved (in direction Z) with respect to cutting tool
mount mechanism 5 (cutting tool 4) by driving mold material mount
mechanism body 10 with the Z-directional driving portion.
[0090] The direction of the axis of rotation of the C-axis itself
is identical (parallel) to direction Z, while mold material 2 (mold
material mount portion 7) can be rotated in a right-handed
(clockwise) rotational direction 18, for example, about the C-axis
serving as rotation center 8 as viewed from the side of cutting
tool 4 (cutting tool mount mechanism 5).
[0091] A desired portion (a locus 21 of a desired position 20
described later, for example) of mold material 2 is rotated about
rotation center 8, to move at a desired rotational speed (desired
traveling speed).
[0092] Cutting tool mount mechanism 5 is provided with a cutting
tool mount portion 11 mounted with cutting tool 4, a cutting tool
mount mechanism body 12 equipped with cutting tool mount portion
11, an X-directional driving portion (not shown) driving cutting
tool mount portion 11 provided on body 12 in direction X, a
Y-directional driving portion (not shown) driving cutting tool
mount portion 11 provided on body 12 in direction Y and an
elliptical vibration generating portion (not shown) provided on
cutting tool mount portion 11 described later.
[0093] In other words, cutting tool 4 (mount portion 11) can be
independently driven and moved in directions X and Y respectively
in cutting tool mount mechanism 5.
[0094] Therefore, a cutting tool locus (spiral locus, for example)
14 having an arbitrary shape can be drawn on work surface 13 at a
desired traveling speed with the forward end (cutting edge) of
cutting tool 4 correspondingly to a cut position on work surface 13
of mold material 2 (to be clockwise identically to rotational
direction 18 of mold material 2, for example).
[0095] Cutting tool locus 14 can be formed by performing cutting
while regularly arranging the position of the cutting edge of
cutting tool 4 on the same side as viewed from the central position
of the opening in the opening (desired range) of cavity 17 formed
in work surface 13 of mold material 2.
[0096] At this time, cutting tool locus 14 can be controlled by
separating or approximating the cutting edge of cutting tool 4 from
or to the central position of the opening.
[0097] In a circular opening, for example, cutting tool locus 14
can be formed by regularly arranging the cutting edge of cutting
tool 4 on the three-o'clock position in the opening regarded as the
face of a clock, while cutting tool locus 14 can be controlled by
approximating the cutting edge of cutting tool 4 from a position on
the outer peripheral edge of the circular opening toward the
central position thereof, for example.
[0098] In cutting/working apparatus 1, directions X, Y and Z
correspond to the horizontal direction, the vertical direction and
the anteroposterior direction respectively with respect to mold
material 2 mounted on mold material mount portion 7, while the
direction of the C-axis (direction Z) is perpendicular to
directions X and Y respectively.
[0099] In cutting/working apparatus 1, further, cutting tool 4 is
longitudinal along direction Z, i.e., the direction of the depth of
cut corresponding to the thickness direction of mold material 2,
while an X-Y plane formed on the forward end (cutting edge) of
cutting tool 4 independently moving in directions X and Y
respectively is rendered parallel to work surface 13 of mold
material 2.
[0100] In practice, work surface 13 is formed by previously turning
mold material 2 before main working, for example, whereby the X-Y
plane formed on the cutting edge of cutting tool 2 is parallel to
work surface 13 of mold material 2.
[0101] The working surface (concave surface, for example) formed in
the depth direction of the desired range (overall surface in the
circular opening, for example) in the opening of cavity 17
including the desiredly shaped opening can be worked/forked by
reciprocating the cutting edge of cutting tool 4 in direction
Z.
[0102] Therefore, cavity 17 for molding an optical component (for
molding a Fresnel lens, for example) including the desiredly shaped
opening and the desiredly shaped working surface (concave surface
or the like) can be formed on desired position 20 (at a desired
distance 16 from rotation center 8) of work surface 13 in rotated
mold material 2 with (the cutting edge of) cutting tool 4, as
described later.
[0103] A locus 15 of the elliptical vibration generated on the
cutting edge of cutting tool 4 by the elliptical vibration
generating portion is formed on a Y-Z plane, as described
later.
[0104] As hereinabove described, cutting tool locus 14 is formed on
the cutting edge of cutting tool 4 due to the control instruction
from the control mechanism of cutting/working apparatus 1 while a
locus (locus 21 of desired position 20, for example) is formed on
the cut position of work surface 13 of mold material 2 (mold
material mount portion 7) due to the control instruction.
[0105] Therefore, a cutting speed (see arrow 24 shown in FIG. 7A)
can be relatively formed between cutting tool 4 (locus 14) and mold
material 2 (locus 21) due to the control instruction from the
control mechanism of cutting/working apparatus 1.
(Cutting with Lathe-Type Cutting/Working Apparatus)
[0106] In lathe-type cutting/working apparatus 1, mold material 2
is first mounted on mold material mount portion 7 and rotated about
rotation center 8 of the C-axis. Thus, mold material 2 (mold
material mount portion 7) is rotated, and advanced toward cutting
tool 4 (direction Z) with the Z-directional driving portion.
[0107] Then, the cutting edge of cutting tool 4 is moved along
cutting tool locus 14 formed by the driving in directions X and Y
at the desired traveling speed and adjusted to be reciprocative in
the direction (direction Z) of the depth of cut corresponding to
the thickness direction of mold material 2. Thus, desired position
20 separated from rotation center 8 by desired distance 16 can be
cut on work surface 13 of rotated mold material 2.
[0108] At this time, elliptical vibration locus 15 is formed on the
cutting edge of cutting tool 4 by the elliptical vibration
generating portion as described above, whereby desired position 20
of work surface 13 of mold material 2 can be elliptically
vibrated/cut, and cavity 17 for molding an optical component (for
molding a Fresnel lens) including the desiredly shaped opening and
the desiredly shaped working surface can be formed on desired
position 20.
[0109] Therefore, a desired number (a plurality) of Fresnel lens
molding cavities 17 can be formed on work surface 13 of mold
material 2, for obtaining a Fresnel lens mold (split mold 19) shown
in FIG. 9.
[0110] The "desired cutting speed" (by the vibration locus
according to the present invention) can be relatively (and
sufficiently) efficiently formed between mold material 2 and
cutting tool 4 by the relative cutting feed rate resulting from the
desired traveling speed (desired rotational speed) in mold material
2 and the desired traveling speed in cutting tool 4 and the desired
vibration speed on the locus (15) of the elliptical vibration on
the three-o'clock position in the cavity opening in cutting of
cavity 17, as described later.
(Cutting Tool Locus on Work Surface of Mold Material)
[0111] Cutting tool locus 14 is now described (refer to FIG.
5).
[0112] As hereinabove described, the forward end of cutting tool 4
can be independently moved in directions X and Y respectively in
four-spindle lathe-type cutting/working apparatus 1, while the
forward end (cutting edge) of cutting tool 4 can be (rotationally)
moved at the desired traveling speed along cutting tool locus
(spiral locus, for example) 14, as shown in FIG. 5.
[0113] According to this embodiment, the cutting edge of cutting
tool 4 is located on the three-o'clock position in the cavity
opening.
[0114] Referring to the position of an arbitrary point on work
surface 13 of mold material 2 such as desired position 20 for
cutting cavity 17, for example, desired position 20 is separated
from the position of rotation center 8 of the C-axis on work
surface 13 of mold material 2 by desired distance 16.
[0115] When mold material 2 mounted on mold material mount portion
7 is rotated about rotation center 8 of the C-axis, therefore, the
arbitrary point on work surface 13 of rotated mold material 2
(rotationally) moves along locus 21 of a circle having a radius
corresponding to desired distance 16 at the desired rotational
speed (desired traveling speed or peripheral speed) while holding
desired distance 16 between position 20 of the arbitrary point and
the position of rotation center 8 as the radius.
[0116] In other words, the forward end of cutting tool 4 is rotated
(clockwise or counterclockwise) in alignment with position 20 of
the arbitrary point to be synchronized with position 20 of the
arbitrary point and to follow the same, whereby the forward end
(cutting edge) of cutting tool 4 can be rotationally moved along
circular locus 14 having the radius corresponding to desired
distance 16.
[0117] In the state of this rotation in alignment, therefore,
position 20 of the arbitrary point on work surface 13 of rotated
mold material 2 and the position of the forward end of rotated
cutting tool 4 are in relatively stopped states.
[0118] In the state of this rotation in alignment (relatively
stopped states), the cutting edge of cutting tool 4 is so
arbitrarily moved with respect to mold material 2 (work surface 13)
that the relative cutting feed rate (moving locus) can be formed
between mold material 2 and cutting tool 4 by the desired traveling
speeds (loci) of mold material 2 and cutting tool 4, as described
later.
[0119] Cavity 17 having the desired shape can be formed on desired
position 20 of work surface 13 of mold material 2 by cutting at the
relative cutting feed rate (moving locus).
[0120] At this time, further, the desired cutting speed (vibration
locus) can be relatively formed by the relative cutting feed rate
resulting from the desired traveling speeds (loci) of mold material
2 and cutting tool 4 and the vibration speed of the locus of the
elliptical vibration described later.
[0121] As hereinabove described, work surface 13 of mold material 2
can be cut with cutting tool 4 at the relatively formed desired
cutting speed (24) by moving the cutting edge of cutting tool 4
from the position on the peripheral edge of the opening toward
central position 20 thereof in the three o'clock direction in the
opening of cavity 17 cut on desired position 20 of rotated mold
material 2 (work surface 13), for example.
[0122] As hereinabove described, further, a working surface can be
cut on work surface 13 by moving mold material 2 in direction Z
thereby adjusting the depth of cut from work surface 13, for
example.
[0123] Therefore, cavity 17 having the desiredly shaped opening and
the desiredly shaped working surface can be cut on position 20 of
the arbitrary point of work surface 13 of mold material 2 with the
cutting edge of cutting tool 4 by synchronous control at the
relative desired cutting speed (vibration locus) formed by the
traveling speed (locus) of rotated mold material 2 and the
vibration speed of the locus of the elliptical vibration including
the cutting edge (locus) of moved cutting tool 4, as described
later.
[0124] Referring to FIGS. 6A and 6B, the relative desired cutting
feed rate formed on an arbitrary position in the opening (working
surface) of molding cavity 17 formed on desired position 20 of work
surface 13 of rotated mold material 2 (mold material mount portion
7) separated from rotation center 8 by desired distance 16, for
example, is now described with reference to an alphabetic letter P
in the opening of cavity 17 shown in FIG. 6A and the opening of
cavity 17 shown in FIG. 6B (synchronous control).
[0125] For example, alphabetic letter P located on the three
o'clock position on work surface 13, regarded as the face of a
clock, of mold material 2 mounted on mold material mount portion 7
is successively rotated clockwise upon clockwise rotation (in
right-handed rotational direction 18) of mold material mount
portion 7 to be inverted on the nine-o'clock position of mold
material 2, for example, as shown in FIG. 6A.
[0126] In other words, letter P itself is so successively rotated
clockwise that arbitrary positions on the outer peripheral edge
(circumference) of and in the opening of cavity 17, for example,
are also rotated clockwise, as shown in FIG. 6A.
[0127] Therefore, a (rotational) traveling direction 61 resulting
from the rotation of mold material 2 (mold material mount portion
7) about rotation center 8 in right-handed rotational direction 18
on the three o'clock position in the opening of cavity 17
(rotationally) moved on work surface 13 is regularly downward
(shown by arrow 62) in the example shown in FIG. 6A.
[0128] As shown in FIG. 6A, a desired position (cut position) of
the cutting edge (upper point of triangular cutting tool 4) of
cutting tool 4 is regularly located on the three-o'clock position
in the opening of cavity 17 regarded as the face of a clock, while
this three-o'clock position is located rightward beyond central
position 20 of the opening of cavity 17 regardless of (rotational)
movement of cavity 17.
[0129] In other words, the cutting edge of cutting tool 4 present
on the desired position of the opening in the three-o'clock
direction forms cutting tool locus 14 at the desired traveling
speed.
[0130] Therefore, the relative cutting feed rate (moving locus) can
be obtained by traveling directions 61 and 62 (desired traveling
speed) of mold material 2 and locus 14 (desired traveling speed) of
cutting tool 4.
[0131] Further, the direction of cutting resulting from locus 15 of
the elliptical vibration generated on cutting tool 4 with respect
to mold material 2 (work surface 13) is regularly upward (shown by
arrow 63) in FIG. 6B, as described later.
[0132] Therefore, the desired cutting speed (vibration locus) can
be relatively formed by the relative cutting feed rate resulting
from traveling directions 61 and 62 (desired traveling speed) of
mold material 2 and locus 14 (desired traveling speed) of cutting
tool 4 and direction 63 (desired vibration speed) of the cutting
resulting from elliptical vibration locus 15 in the three-o'clock
direction in the opening of cavity 17, as described later.
[0133] While the cut position (position for setting the cutting
edge of cutting tool 4) in the opening of cavity 17 can
alternatively be regularly set on an arbitrary position such as the
six-, nine- or twelve-o'clock position, cutting tool 4 must be so
arranged that the direction (63) of the cutting along elliptical
vibration locus 15 is opposite to right-handed rotational direction
18 of mold material 2 (mold material mount portion 7).
[0134] In extreme terms, the arbitrary point (position for cutting
mold material 2) in the opening of cavity 17 is regularly rotated
clockwise in this opening, and the "desired cutting speed
(vibration locus)" according to the present invention can be
relatively formed between mold material 2 and cutting tool 4 by
arranging the direction of the cutting along elliptical vibration
locus 15 so that the cutting edge of cutting tool 4 is opposite to
the traveling direction of the arbitrary point in the opening.
(Elliptical Vibration Cutting)
[0135] Elliptical vibration cutting is now described with reference
to FIGS. 7A and 7B.
[0136] As hereinabove described, cutting tool mount portion 11 is
provided with the elliptical vibration generating portion (not
shown) forming and drawing elliptical vibration locus 15 on the
forward end (cutting edge) of cutting tool 4 mounted on cutting
tool mount portion 11.
[0137] Therefore, work surface 13 of mold material 2 can be
elliptically vibrated/cut by forming elliptical vibration locus 15
mechanically resonated/composited by vibrations in directions Y and
Z on the plane formed in directions Y and Z in the elliptical
vibration generating portion.
[0138] The principle of elliptical vibration cutting is now
described with reference to a cutting tool 22 (4) so shaped as to
clearly illustrate this principle.
[0139] In elliptical vibration cutting, a workpiece (mold material)
is elliptically vibrated/cut by a desired undeformed chip thickness
23 with cutting tool 22 (4) in an elliptical vibration state.
[0140] The elliptical vibration generating portion includes
piezoelectric elements (not shown) individually vibrating the
cutting edge of cutting tool 22 (4) in directions Y and Z
respectively, for example, and the piezoelectric elements for
generating vibrations in the two directions Y and Z are so formed
that a prescribed sinusoidal voltage can be individually input
therein at a prescribed frequency (ultrasonic domain, for example)
and a prescribed phase difference (90.degree., for example)
respectively, for example.
[0141] Therefore, elliptical vibration locus 15 having a desired
cycle (ultrasonic domain around 20 KHz, for example) can be formed
on the cutting edge of cutting tool 22 (4) at the "desired
vibration speed" by individually inputting the prescribed
sinusoidal voltage in the respective piezoelectric elements thereby
mechanically resonating/compositing the vibrations generated in the
two directions Y and Z.
[0142] Direction Y corresponds to a cutting direction A and a
cutting force direction B, direction Z corresponds to a thrust
force direction D, and direction X corresponds to a feed force
direction C.
[0143] Further, the direction of (relative desired) cutting speed
24 in mold material 2 is identical to cutting direction A.
[0144] First, the workpiece (mold material 2) is cut with cutting
tool 22 (4) in cutting force direction B (upward in FIG. 7A) along
elliptical vibration locus 15.
[0145] Upward cutting force direction B shown in FIG. 7A defines
the cutting direction (63) in elliptical vibration locus 15.
[0146] Then, cutting tool 22 (4) is separated from workpiece 2 in
thrust force direction D (rightward in FIG. 7A).
[0147] At this time, cutting tool 22 (4) pulls up a chip 25 cut off
from workpiece 2 in thrust force direction D (rightward in FIG. 7A)
thereby discharging chip 25 in a chip discharge direction E,
whereby frictional resistance against elliptical vibration cutting
is reduced or inverted (to negative frictional resistance) as
compared with ordinary cutting.
[0148] In other words, cutting resistance of workpiece 2 against
cutting tool 22 (4) is reduced, while cutting force of cutting tool
22 (4) can be reduced for improving machinability.
[0149] Then, cutting tool 22 (4) is separated from chip 25 in
cutting force direction B (downward in FIG. 7A) (rightward in FIG.
7B), and moved in thrust force direction D (leftward in FIG. 7A),
i.e., toward workpiece 2.
[0150] Therefore, workpiece 2 can be elliptically vibrated/cut and
worked by periodically vibrating cutting tool 22 (4) along
elliptical vibration locus 15.
[0151] The aforementioned elliptical vibration cutting has such
advantages that the thickness (23) of chip 25 is reduced as
compared with ordinary cutting, cutting resistance can be reduced
while the working surface can be mirror-finished, the life of
cutting tool 22 (4) is increased, precision in the worked shape is
improved, formation of mold flashes is suppressed, chattering
vibration is prevented, and cutting heat is reduced.
[0152] According to a conventional cutting method, workpiece 2 is
cut with cutting tool 22 (4) in a compressed state, whereby cutting
resistance is increased and chip 25 is compressed into powder to
form mold flashes on the cut surface of workpiece 2.
[0153] In the elliptical vibration cutting, however, cutting tool
22 (4) can pull up chip 25, whereby a shear angle is increased,
cutting resistance is reduced, chip 25 can be continuously formed
(in an elongated shape, for example) to be discharged (referred to
as a continuous ductility mode), formation of mold flashes can be
suppressed, and the cut surface of workpiece (mold material) 2 can
be mirror-finished.
[0154] Numeral 26 denotes the shear angle.
(Structure of Compression Mold Comprising Split Mold)
[0155] The structure of a compression mold (optical component mold)
31 detachably comprising split mold 19 (see FIG. 9) having a
desired number of Fresnel lens molding cavities 17 is now described
with reference to FIG. 10.
[0156] Compression mold (Fresnel lens mold) 31 comprising split
mold 19 is constituted of an upper mold section 32 and a lower mold
section 33, for example, while a substrate supply portion 36
supplying/setting a substrate 35 mounted with optical elements
(electronic components) 34 such as LEDs is provided on upper mold
section 32.
[0157] Lower mold section 33 is provided with a general cavity 37
collectively compression-molding optical elements 34 mounted on
substrate 35, while split mold 19 (see FIG. 9) provided with
discrete cavities (cavities) 17 corresponding to optical elements
34 respectively is detachably provided in general cavity 37.
[0158] Lower mold section 33 is further provided with a pressing
member 38 pressing a resin material heated/melted in general cavity
37 (cavities 17) through split mold 19.
[0159] Therefore, optical elements 34 can be individually
compression-molded in cavities 17 of general cavity 37 by dipping
optical elements 34 mounted on substrate 35 supplied to substrate
supply portion 36 of upper mold section 32 into the resin material
heated/melted in general cavity 37 and pressing the resin material
in general cavity 37 with pressing member 38.
[0160] A work surface 13 of split mold 19 defines the bottom
surface of general cavity 37 in mold 31 (lower mold section
33).
(Elliptical Vibration Cutting of Cavity)
[0161] In other words, compression mold 31 (refer to FIG. 10)
comprising split mold 19 (refer to FIG. 9) having cavities 17 for
molding a desired number of Fresnel lenses, for example, can be
formed by elliptically vibrating/cutting desired position 20 of
work surface 13 of mold material (workpiece) 2 with cutting tool 22
(4).
[0162] Further, formation of mold flashes can be efficiently
prevented in Fresnel lens molding cavities 17 (Fresnel lens molding
surfaces) by the elliptical vibration cutting as compared with
ordinary cutting, and the Fresnel lens molding surfaces can be
efficiently mirror-finished by the elliptical vibration
cutting.
[0163] In other words, mold 31 (split mold 19) capable of
resin-molding resin Fresnel lenses (plastic Fresnel lenses)
improvable in light transmission property can be worked by forming
the Fresnel lens molding surfaces through elliptical vibration
cutting of mold material 2.
[0164] Therefore, split mold 19 comprising the Fresnel lens molding
surfaces is detachably mounted on compression mold (31) shown in
FIG. 10 so that resin Fresnel lenses can be compression-molded with
mold (31), as described later.
[0165] In other words, the Fresnel lens molding surfaces (mirror
surfaces) can be transferred to resin Fresnel lens surfaces,
thereby mirror-finishing the resin Fresnel lens surfaces forming
the transferred surfaces.
[0166] The resin Fresnel lens surfaces are so mirror-finished as to
eliminate a factor inhibiting light passing through the resin
Fresnel lens surfaces by transfer of mold flashes in the
aforementioned prior art, whereby the light transmission property
on the resin Fresnel lens surfaces can be improved.
[0167] Therefore, the light transmission property can be improved
in the entire resin Fresnel lenses formed by mold 31 elliptically
vibrated/cut as compared with resin Fresnel lenses formed by a mold
worked by the conventional cutting method.
(Working of Peripheral Groove in Fresnel Lens Mold)
[0168] Working of peripheral grooves formed in Fresnel lens mold 31
is now described with reference to FIGS. 8A and 8B.
[0169] FIGS. 8A and 8B show mold material 2 (section) having
peripheral grooves 43 and 47 formed by cutting tools 41 and 44 (4)
respectively. The Y-Z plane on which elliptical vibration locus 15
is formed is perpendicular to the horizontal planes shown in FIGS.
8A and 8B.
[0170] Referring to FIGS. 8A and 8B, arrows show movements of
cutting tools 41 and 44 (4) in cutting.
[0171] Peripheral grooves 43 and 47 of mold 31 are transferred to
the resin Fresnel lenses in an inverted manner.
[0172] In the example shown in FIG. 8A, cutting tool 41 (4)
including a cutting edge having a shape similar to that of
peripheral grooves 43 in section is employed.
[0173] When mold material 2 is cut with cutting tool 41 (4) at a
relative desired cutting speed as shown in FIG. 8A, for example,
peripheral grooves 43 having a desired depth (direction Z) can be
cut by a desired number correspondingly to the shape of the cutting
edge of cutting tool 41 (4) individually and successively stepwise
in the similar shape.
[0174] At this time, elliptical vibration (locus 15) is applied to
the cutting edge of cutting tool 41 (4), so that peripheral grooves
43 can be elliptically vibrated/cut.
[0175] When the Fresnel lens mold is worked, therefore, cutting
resistance is reduced, chips can be continuously formed and
discharged, formation of flashes can be suppressed and peripheral
grooves 43 of mold material 2 can be mirror-finished, as
hereinabove described.
[0176] Referring to FIG. 8B, on the other hand, cutting tool 44 (4)
is employed.
[0177] When mold material 2 is cut with cutting tool 44 (4) at a
relative desired cutting speed as shown in FIG. 8B, for example,
peripheral grooves 47 can be individually and successively cut
stepwise in two stages along leftward arrow 45 and upward arrow 46
shown in FIG. 8B.
[0178] At this time, elliptical vibration (locus 15) is applied to
the cutting edge of cutting tool 44 (4), so that peripheral grooves
47 can be elliptically vibrated/cut.
[0179] Therefore, peripheral grooves 47 of mold material 2 can be
mirror-finished with cutting tool 44 shown in FIG. 8B through a
function/effect similar to that in FIG. 8A.
[0180] Referring to FIGS. 8A and 8B, surfaces (curved surfaces) of
cavities 17 for forming peripheral grooves 43 and 47 may be formed
by the elliptical vibration cutting according to the present
invention before cutting peripheral grooves 43 and 47.
(Calculation of Locus of Cutting Tool and Control Instruction in
Working of Fresnel Lens Mold)
[0181] An exemplary calculation (control instruction) of the locus
of cutting tool 4 is now described with reference to FIG. 11.
[0182] Four-spindle lathe-type cutting/working apparatus 1 shown in
FIG. 1 is employed in the present invention as hereinabove
described, while a position O.sub.j (desired position 20) separated
from the core O (rotation center 8) of the C-axis by a radius
R.sub.j (desired distance 16) is set in rectangular coordinates (X,
Y, Z) with reference to the origin formed by the core O (central
position of spindle rotation) of the C-axis.
[0183] In other words, the shape of the opening of Fresnel lens
mold cavity 17 located on position O.sub.j of mold material 2 (mold
material mount portion 7) separated from core O (rotation center 8)
of the C-axis by desired distance R.sub.j (16) is expressed as
follows:
Z ( r j ) = mod [ f ( r j ) , b ] ( 1 ) f ( r j ) = C v r j 2 1 + 1
- C v 2 ( 1 + C c ) r j 2 + i = 3 m C i r j i ( 2 ) r j 2 = ( X -
Xo j ) 2 + ( Y - Yo j ) 2 , j = 0 , 1 , 2 , n ( 3 )
##EQU00001##
[0184] Referring to the expressions (1), (2) and (3), x, y and z
denote the coordinates of mold material (workpiece) 2 in directions
X, Y and Z respectively. b denotes a step, r.sub.j denotes the
distance from the lens center, i denotes an order, j denotes the
number of each lens, and (Xo.sub.j, Yo.sub.j) denotes the central
coordinates of the lens. C.sub.v denotes approximate curvature,
C.sub.c denotes a coefficient of cone, and C.sub.j denotes a
working point of each lens, wherein approximate curvature C.sub.v
is equal to 1/R (R: approximate radius of curvature). All of these
constants stand for those of the configuration of the original
aspheric lens having the shape of Fresnel lens.
[0185] Assuming that (Xo.sub.j, Yo.sub.j) denotes the central
coordinates of the lens j as shown in FIG. 11, polar coordinates
(R.sub.j, .alpha..sub.j) can be expressed as follows:
R j = Xo j 2 + Yo j 2 ( 4 ) .alpha. j = tan - 1 Yo j Xo j ( 5 )
##EQU00002##
[0186] Assuming that .theta. represents the rotation angle
(degrees) at core O (rotation center 8) of the C-axis of mold
material 2 (mold material mount portion 7), T represents the
rotational speed (rpm) of the C-axis, r.sub.o represents the radius
of lens j and F represents the relative feed rate (mm/min.) of
cutting tool 4 on lens j, polar coordinates (r.sub.j,
.theta..sub.j) showing the position of the cutting edge of cutting
tool 4 with reference to center O.sub.j (desired position 20) of
lens j is expressed as follows:
( r j , .theta. j ) = ( r j 0 - F T .theta. , .pi..theta. 180 ) ( 6
) ##EQU00003##
[0187] Therefore, position coordinates instructed and transmitted
as the control instruction from the control mechanism to
four-spindle lathe-type cutting/working apparatus 1 according to
this embodiment are expressed as follows:
X:R.sub.jcos(.alpha..sub.j-.theta..sub.j)+r.sub.j (7)
Y:R.sub.jsin(.alpha..sub.j-.theta..sub.j) (8)
Z:Z(r.sub.j) (9)
C:.theta. (10)
[0188] Referring to FIG. 11, points C.sub.j,C.sub.j' in the two
circle respectively denote working points, and the arrow in the
lower circle (showing the shape of the opening of cavity 17) shows
the locus of the cutting edge of cutting tool 4. In this case, the
cutting edge of cutting tool 4 is regularly set on the
three-o'clock position in the circular opening of cavity 17
(regarded as the face of a clock), for example.
[0189] Split mold 19 can be formed by repeating the aforementioned
working with the control instruction by the number n of the lenses
thereby forming the desired number of Fresnel lens mold cavities 17
on mold material 2 (work surface 13).
(Shape of Opening in Cavity and Shape of Working Surface)
[0190] The case of elliptically vibrating/cutting cavity 17 of the
desired shape with lathe-type cutting/working apparatus 1 capable
of forming elliptical vibration locus 15 on the cutting edge of
cutting tool 4 (41, 44) at the "desired vibration speed" as
hereinabove described is now described.
[0191] First, the desired control instruction is transmitted to
apparatus 1, for rotating mold material 2 (mold material mount
portion 7) and moving the same to the desired position (20) at the
desired distance (16) from rotation center 8 along locus 21 at the
"desired traveling speed", while moving the cutting edge of cutting
tool 4 (41, 44) along cutting tool locus 14 at the "desired
traveling speed".
[0192] Then, desired position 20 of work surface 13 of rotated mold
material 2 is elliptically vibrated/cut with cutting tool 4 (41,
44), so that (single) cavity 17 having the desiredly shaped opening
can be formed on desired position 20 of mold material 2 and cavity
17 has the working surface (concave surface, for example) of the
desired shape.
[0193] At this time, the "desired cutting speed (vibration locus)"
according to the present invention is relatively formed by the
relative cutting feed rate resulting from the desired traveling
speeds of mold material 2 and cutting tool 4 (41, 44) and the
vibration speed of elliptical vibration locus 15.
[0194] In other words, the opening of cavity 17 can be formed in an
arbitrary shape on work surface 13, while the working surface
(concave surface) of cavity 17 can also be formed in an arbitrary
shape according to this embodiment.
[0195] For example, the opening of cavity 17 can be circularly or
elliptically formed, while the working surface of cavity 17 can be
worked into a desired curved shape, a nonspherical shape, a curved
shape having concentric peripheral grooves (43, 47) or the like.
Thus, the opening and the working surface of cavity 17 can be
worked into various shapes.
[0196] When the interval between the centers of cavities 17 is
reduced below the diameter of the opening of cavity 17, a
complicated shape can be formed by superposing the aforementioned
shapes.
(Function)
[0197] According to this embodiment, as hereinabove described,
cavity 17 having the desiredly shaped opening and the desiredly
shaped working surface can be cut on the desired position
(arbitrary position) of moved work surface 13 (mold material 2) by
elliptical vibration (locus 15) with moved cutting tool 4 at the
relative desired cutting speed (24), thereby obtaining split mold
(optical component mold) 19 having the desired number of cavities
17.
[0198] In other words, mold material 2 may simply be mounted on
mold material mount portion 7 once according to this embodiment,
whereby cavity parts 108 may not be worked one by one and mold
material 102 may not be shifted for working each cavity 106
dissimilarly to the prior art.
[0199] Therefore, neither setup time of the apparatus nor assembly
time for the cavity block is necessary, whereby the mold can be
manufactured in a shorter time than the prior art so that the
productivity of the optical component mold can be efficiently
improved.
[0200] According to this embodiment, mold material 2 can be cut
with cutting tool 4 at the relative desired cutting speed while the
working surface of cavity 17 can be elliptically vibrated/cut,
whereby the working surface of the mold can be mirror-finished.
[0201] Therefore, a high-quality working surface can be efficiently
worked in working of the optical component mold according to the
present invention.
[0202] While only cavity 106 having the axisymmetric circular
opening and the spherical working surface is worked at rotation
center 105 in the prior art, cavity 17 including the desiredly
shaped opening and the desiredly shaped working surface is formed
on desired position 20 of mold material 2 separated from rotation
center 8 by desired distance 16 according to the present invention,
whereby cavity 17 including the desiredly shaped opening and the
nonspherical working surface (concave surface) can be efficiently
worked.
(Method of Working Optical Component Mold)
[0203] A method of working an optical component mold is now
described with reference to FIGS. 3A (1), 3B (2), 4A (1) and 4B
(2).
[0204] In this case, cavity 17 including the desiredly shaped
opening and the desiredly shaped working surface (concave surface)
is formed on desired position 20 on work surface 13 of mold
material 2 mounted on mold material mount portion 7 separated from
rotation center 8 by desired distance 16 at the relative desired
cutting speed (vibration locus) according to the present invention
by elliptical vibration cutting.
[0205] First, mold material 2 is mounted on mold material mount
portion 7 provided on four-spindle lathe-type cutting/working
apparatus 1 and rotated about rotation center 8 of the C-axis (in
right-handed rotational direction 18 in FIG. 3A to 4B) and
rotationally moved to desired position 20 (position for forming
cavity 17 by cutting) at desired distance 16 from rotation center 8
of work surface 13 of mold material 2 at the desired traveling
speed along locus 21.
[0206] Then, the cutting edge of cutting tool 4 is regularly set on
the three-o'clock position in the opening of cut cavity 17 while
cutting tool 4 is independently moved in directions X and Y
respectively, thereby moving the cutting edge of cutting tool 4 at
the desired traveling speed along cutting tool locus 14.
[0207] At this time, the desired cutting feed rate (moving locus)
can be relatively formed between the arbitrary point in cavity 17
and cutting tool 4 by synchronously controlling cutting tool 4 to
follow mold material 2 in cutting/working apparatus 1.
[0208] Then, work surface 13 (20) of mold material 2 can be
elliptically vibrated/cut in cutting of cavity 17 by forming
elliptical vibration locus 15 on the cutting edge of cutting tool
4.
[0209] At this time, the "desired cutting speed" by the vibration
locus according to the present invention can be relatively (and
sufficiently) efficiently formed between mold material 2 and
cutting tool 4 by the desired cutting feed rate resulting from the
desired traveling speed (desired rotational speed) of mold material
2 and the desired traveling speed of cutting tool 4 and the desired
vibration speed in elliptical vibration locus 15.
[0210] Therefore, the working surface of the mold can be
efficiently mirror-finished at the relative desired cutting speed
(vibration locus) by cutting mold material 2 with cutting tool 4
and elliptically vibrating/cutting mold material 2.
[0211] As hereinabove described, the cutting edge of cutting tool 4
independently driven in directions X and Y respectively can be
moved along arbitrary cutting tool locus 14, whereby cavity 17
including the desiredly shaped opening can be formed on desired
position 20 on work surface 13 of mold material 2 separated from
rotation center 8 by desired distance 16.
[0212] Further, cavity 17 including the desiredly shaped working
surface can be formed by moving cutting tool 4 in direction Z, as
hereinabove described.
[0213] Therefore, a cavity having a desired shape, i.e., optical
component molding cavity 17 including the desiredly shaped opening
and the desiredly shaped working surface (concave surface, for
example) can be formed on a desired portion of work surface 13 of
mold material 2 by cutting.
[0214] Further, a mold (split mold 19) having a desired number of
cavities 17 (structure obtained by arranging a plurality of
cavities 17 in the form of a matrix, for example) is cut by
repeating the working according to the present invention for
forming a desired number of cavities 17 on desired position (20) of
mold material 2.
[0215] In order to work a Fresnel lens mold (optical component
mold) by the aforementioned working method, the working described
with reference to FIGS. 8A and 8B, for example, is performed.
[0216] Further, the control instruction described with reference to
FIG. 11 can be employed as the aforementioned control instruction
for working cavity 17.
[0217] In other words, neither setup time of the apparatus nor
assembly time for the cavity block is necessary according to this
embodiment as hereinabove described, whereby the mold can be worked
in a shorter time than the prior art so that the productivity of
the optical component mold can be efficiently improved.
[0218] According to this embodiment, the working surface of the
mold can be mirror-finished by forming cavity 17 of the desired
shape by elliptically vibrating/cutting mold material 2 at the
relative desired cutting speed, whereby a high-quality working
surface can be efficiently worked in the working of the optical
component mold according to the present invention.
[0219] According to this embodiment, further, cavity 17 including
the nonspherical working surface (concave surface) can be
efficiently worked.
[0220] In order to cut a hardly cuttable material such as cemented
carbide, for example, as mold material 2 in this embodiment, the
cutting edge of cutting tool 4 is driven in directions X and Y
along cutting tool locus 14 as the tool feed according to the
present invention, as hereinabove described.
[0221] In the point cutting work surface 13 (mold material 2) and
mirror-finishing the working surface, however, it may not be
possible to efficiently obtain the (relatively formed) desired
cutting speed (24) on cutting tool 4 with respect to mold material
2 (cut position on work surface 13) in the tool feed in
cutting/working apparatus (1).
[0222] In other words, the cutting edge of cutting tool 4 is
inverted on a position along direction X or Y while the hardly
cuttable material (mold material 2) cut with cutting tool 4 is
extremely hard, whereby it may not be possible to efficiently
(sufficiently) obtain the relative desired cutting speed on cutting
tool 4 in the point of formation of the relative desired cutting
speed.
[0223] In the case of cutting the hardly cuttable material (mold
material 2), therefore, ultrasonic elliptical vibration is further
supplied to the cutting edge of cutting tool 4, so that the
(relatively formed) desired cutting speed with respect to mold
material 2 can be (sufficiently) efficiently obtained on cutting
tool 4.
[0224] Referring to FIG. 7A, the cutting feed rate for mold
material (workpiece) 2 in cutting direction A (downward in FIG. 7A)
is obtained by compositing the desired traveling speeds of rotated
mold material 2 and the cutting edge of cutting tool 22 (4), and
the relative desired cutting speed (24) can be efficiently
(sufficiently) obtained by the desired vibration speed in the
direction (upward in FIG. 7A) opposite to cutting direction A in
elliptical vibration locus 15 formed on cutting tool 22 (4).
[0225] According to the present invention, therefore, the "relative
desired cutting speed" can be efficiently obtained by the "relative
cutting feed rate resulting from traveling speed 61 or 62 (locus
21) of mold material 2 and the traveling speed (locus 14) of the
cutting edge of cutting tool 4" and "vibration speed 63 of
elliptical vibration locus 15" on the cut position (three-o'clock
position in the cavity opening) of rotated mold material 2 (work
surface 13).
[0226] In other words, cavity 17 including the desiredly shaped
opening and the desiredly shaped working surface can be cut at the
relative desired cutting speed (vibration locus) according to the
present invention by cutting desired position 20 of rotated mold
material 2 (work surface 13) and elliptically vibrating/cutting
desired position 20 in this cutting, so that the working surface
(desiredly shaped concave surface) of cavity 17 can be efficiently
mirror-finished.
[0227] According to this embodiment, ferrous mold material 2
including soft metal, electroless nickel, cemented carbide, a
tungsten alloy or hardened steel can be cut with a
single-crystalline diamond tool (cutting tool 4, 22) having a sharp
forward end (cutting edge), while a material hardly cuttable by
ordinary cutting can be cut.
[0228] According to this embodiment, hardened steel (mold material
2) can be cut, whereby the present invention is applicable to
working of an optical component mold (for an LED, for example)
capable of efficiently improving productivity.
[0229] In other words, a mold (31) obtained by arranging fine
cavities (17) each having a complicated shape in the form of a
matrix can be worked according to this embodiment, whereby the
present invention can be extended to application related to
LEDs.
[0230] A tool having a V-shaped cutting edge or a rounded-corner
tool having a rounded cutting edge can be employed as cutting tool
4.
[0231] Exemplary cutting data are as follows:
[0232] Mold material (workpiece): Ni--P-plated steel
[0233] Cutting tool: single-crystalline diamond tool
[0234] Speed of spindle rotation (C-axis): 0.1 to 60 rpm
[0235] Diameter of elliptical vibration locus: 1 to 10 .mu.m
[0236] Frequency of elliptical vibration: 20 to 40 kHz
[0237] Vibration speed: 5 to 50 m/min.
Second Embodiment
[0238] A second embodiment of the present invention employing
high-speed milling in place of working by elliptical vibration
cutting is now described with reference to FIGS. 12A and 12B.
[0239] The basic structure of a lathe-type working apparatus 51
employed in the second embodiment is identical to that of
cutting/working apparatus 1 according to the first embodiment.
Therefore, identical portions are denoted by the same reference
signs, and redundant description is not repeated.
(Structure of Lathe-Type Working Apparatus 51 According to Second
Embodiment)
[0240] Lathe-type working apparatus 51 shown in FIG. 12A is
provided with a mold material mount portion 7 mounted with a mold
material 2 and a rotary cutting mechanism 53 having a rotary
cutting tool 52 for high-speed milling.
[0241] According to the second embodiment, a rotary blade 55
provided on the forward end of rotary cutting tool 52 is employed
in place of the vibration speed of elliptical vibration locus 14
according to the first embodiment, and rotary blade 55 is rotated
at a desired rotational speed (along a desired rotation locus).
[0242] In lathe-type working apparatus 51, mold material 2 (cut
position) mounted on mold material mount portion 7 can be rotated
in a right-handed rotational direction 18 about the C-axis serving
as the core (rotation center 8), similarly to cutting/working
apparatus 1 according to the first embodiment.
[0243] Rotary cutting tool 52 for high-speed milling is
independently driven in directions X and Y respectively, to be
movable along a locus 54 in a state rotated in a rotational
direction 56.
[0244] According to the second embodiment, a cavity 17 including a
desiredly shaped opening and a desiredly shaped working surface
(concave surface) is formed on a desired position 20 at a desired
distance 16 from rotation center 8 on work surface 13 of rotated
mold material 2 by cutting, similarly to the first embodiment.
[0245] According to the second embodiment, desired position 20
rotationally moves along a locus 21 due to the rotation about
rotation center 8, while rotary blade 55 of rotary cutting tool 52
is located on the three-o'clock position in the opening of cavity
17 and controlled to be approximated to or separated from the
central position (desired position 20) of the opening of cavity 17
(see locus 54), for example, similarly to the first embodiment.
[0246] In other words, rotary cutting tool 52 is rotated at a high
speed for cutting mold material (workpiece) 2 at a high speed by
the aforementioned milling.
[0247] According to the aforementioned milling, cutter paths are
finely set on the workpiece (2), so that the workpiece (2) can be
worked into a desired shape with small cutting force by rotating
small-diametral rotary cutting tool (54) along the cutter paths at
a high speed (by rapid feed).
[0248] Therefore, the working surface formed by high-speed cutting
with rotary cutting tool 52 can be efficiently mirror-finished.
[0249] In the aforementioned high-speed cutting, the diameter of
rotary cutting tool 52 and the depth of cut in the axial direction
are set to small values with respect to workpiece 2 in order to
stably cut workpiece (mold material) 2 with small cutting force, so
that the working surface of workpiece 2 can be efficiently
mirror-finished.
[0250] According to the second embodiment, therefore, the
productivity of an optical component mold can be efficiently
improved while a high-quality working surface can be efficiently
worked in working of the optical component mold, similarly to the
first embodiment.
[0251] According to the second embodiment, further, cavity 17
having the desiredly shaped opening and a nonspherical working
surface can be efficiently worked, similarly to the first
embodiment.
[0252] In relation to the rotation of rotary blade 55, mold
material 2 (work surface 13) can be subjected to fly cutting (in
other words, up cut milling or down cut milling), for example.
[0253] In other words, mold material 2 is rotated clockwise so that
an arbitrary point in the opening of cavity 17 is moved in the
clockwise (rotational) direction at a desired traveling speed of
this opening, as shown in FIG. 12B (see arrow 59).
[0254] Therefore, mold material 2 (cut position) is moved downward
(along arrow 58) in FIG. 12B on desired position 20 (cut position)
in the opening of cavity 17, as shown in FIG. 12B.
[0255] Further, rotary cutting tool 52 is moved along rotary
cutting tool locus 54 at the desired traveling speed, similarly to
locus 14 of cutting tool 4 according to the first embodiment.
[0256] Therefore, a relative desired cutting speed (moving locus)
can be efficiently obtained by desired traveling speeds 58 and 59
in mold material 2 and the desired rotational speed (locus 54) in
the rotary blade 55, similarly to the first embodiment.
[0257] Further, the "desired cutting speed (rotation locus)"
according to the present invention can be relatively formed by the
relative cutting feed rate resulting from the desired traveling
speeds of mold material 2 and rotary cutting tool 52 and the
desired rotational speed in rotary blade 55, similarly to the first
embodiment.
[0258] The relation between the direction of cutting in the
direction of rotation (rotation locus) of rotary blade 55 on the
three-o'clock position of mold material mount portion 7 (mold
material 2) and the direction of movement of mold material 2 also
applies to another position such as the 0-, six- or nine-o'clock
position of mold material mount portion 7 (mold material 2), for
example.
[0259] The structure according to the second embodiment effectively
acts on a hardly cuttable material, similarly to the first
embodiment.
(Method of Working Optical Component Mold According to Second
Embodiment)
[0260] The working method according to the second embodiment is now
described with reference to FIGS. 12A and 12B.
[0261] According to the second embodiment, mold material 2 is
mounted on mold material mount portion 7 provided on lathe-type
working apparatus 51 and rotated (counterclockwise 18 in FIG. 12A)
about rotation center 8 of the C-axis while desired position 20
(position for forming cavity 17 by cutting) of work surface 13 of
mold material 2 at desired distance 16 from rotation center 8 is
rotated/moved along locus 21, similarly to the first
embodiment.
[0262] Then, rotary cutting tool 52 of lathe-type working apparatus
51 is independently moved in directions X and Y respectively, so
that rotary cutting tool 52 of rotary cutting mechanism 53 is moved
along rotary cutting tool locus 54 such as a spiral locus, for
example.
[0263] In other words, the desired cutting feed rate (moving locus)
can be relatively formed between mold material 2 and rotary cutting
tool 52 of rotary cutting mechanism 53 by synchronously controlling
rotary cutting tool 52 of rotary cutting mechanism 53 to follow
mold material 2 in lathe-type working apparatus 51.
[0264] At this time, rotary blade 55 of cutting tool 52 of
lathe-type working apparatus 51 is regularly set on the
three-o'clock position in the opening of cavity 17.
[0265] At this time, further, the "desired cutting speed (rotation
locus)" according to the present invention can be relatively formed
by the relative cutting feed rate resulting from the desired
traveling speeds of mold material 2 and rotary cutting tool 52 and
the desired rotational speed in rotary blade 55.
[0266] Therefore, desired position 20 of work surface 13 of mold
material 2 can be cut by high-speed milling at the relatively
formed desired cutting speed (rotation locus) according to the
present invention with rotary cutting tool 52 of rotary cutting
mechanism 53.
[0267] At this time, cutting in the direction of depth of cut from
work surface 13 of mold material 2 is performed by moving mold
material 2 in direction Z, similarly to the first embodiment.
[0268] Therefore, high-speed milling is performed on work surface
13 of mold material 2 as described above, whereby cavity 17
including the desiredly shaped opening and the desiredly shaped
working surface (concave surface) such as a nonspherical working
surface, for example, can be formed on desired position 20 of work
surface 13.
[0269] Further, a split mold 19 (optical component mold or
structure) can be obtained by forming a desired number of cavities
17 in work surface 13 of mold material 2 by repeating the working
of forming cavity 17 on desired position 20.
[0270] According to the second embodiment, therefore,
functions/effects similar to those of the first embodiment can be
attained.
[0271] In other words, the mold can be worked in a shorter time
than the prior art according to the second embodiment similarly to
the first embodiment, whereby the productivity of the optical
component mold (structure) can be efficiently improved.
[0272] According to the second embodiment, the working surface of
cavity 17 can be mirror-finished by performing high-speed milling
at the relatively formed desired cutting speed according to the
present invention similarly to the first embodiment, whereby a
high-quality working surface can be efficiently worked in working
of the optical component mold according to the present
invention.
[0273] According to the second embodiment, further, cavity 17
including the desiredly shaped opening and the nonspherical working
surface can be efficiently worked similarly to the first
embodiment.
[0274] In the working method according to each of the
aforementioned embodiments, a mold (split mold) can be formed by
arranging microlens cavities on a mold material in the form of a
matrix.
[0275] While cutting tool 4 and rotary blade 55 are employed in the
aforementioned embodiments, a grinding tool may alternatively be
employed in the present invention.
[0276] While the optical component mold is employed as the
structure in each of the aforementioned embodiments, a metal
component reflecting light, for example, can be formed by working a
metallic material (workpiece).
[0277] While the four-spindle working apparatus having the X-, Y-,
Z- and C-axes is employed in each of the aforementioned
embodiments, a five-spindle working apparatus may alternatively be
employed along with an additional B-axis rotated about the Y-axis
in the present invention.
[0278] Although the present invention has been described and
illustrated in detail, it is clearly understood that the same is by
way of illustration and example only and is not to be taken by way
of limitation, the scope of the present invention being interpreted
by the terms of the appended claims.
* * * * *